Carton construction



Sept. 29, 1970 c; BESSETT ETAL 3,531,039

CARTON CONSTRUCTION Filed Jan. 9, 1969 3 Sheets-Sheet 1 f 6 Q W I l I l l I I l l i I I l l l H h HM].

Sept. 29, 1970 c. BESSETT ETAL 3,531,039

CARTON CONSTRUCTION Filed Jan. 9, 1969 s Sheets-Sheet 5 I I JZ8 HM. M MI. "m

Z W, "Hm WAX United States Patent U.S. Cl. 2292.5 7 Claims ABSTRACT OF THE DISCLOSURE A carton construction is provided with a bottom section and a cover section, the latter being adapted to assume an overlying registered relation with respect to said bottom section. An upstanding wall of the bottom section is provided with spaced upwardly extending first and second protuberances. The first protuberance is provided with a pocket having an outwardly facing open side. The cover section has a depending wall which is adapted to be disposed adjacent to and overlie the open side of said first protuberance pocket, and is adapted to be disposed adjacent to and inwardly of said second protuberance, when the cover section assumes its overlying registered relation with respect to the bottom section. The cover section depending wall is provided with releasable lock means for interlockingly engaging the pocket of the first protuberance.

BACKGROUND OF THE INVENTION In various types of cartons, such as egg cartons made from molded pulp, it is important that the cover section thereof be capable of being readily locked and unlocked with respect to the bottom or tray section with a minimum of manual effort. When locked in a closed position, it is important that the cover section of the carton not be susceptible to accidental opening and that the cover and bottom sections thereof cooperate to provide effective top to bottom strength when loaded cartons are arranged in stacked relation. Furthermore, the closing of the carton must be readily accomplished either manually or with automatic equipment without disturbing or damaging the contents of the carton. Various cartons, such as egg cartons, have heretofore been produced; however, because of certain inherent structural characteristics, they have not been successful in fulfilling the aforementioned requirements. In addition, many of these prior cartons are difficult and costly to produce and/or are not readily capable, when loaded, of being bulk packed in conventional shipping containers.

SUMMARY OF THE INVENTION Thus, it is an object of this invention to provide an attractive, sturdy, yet inexpensive carton Which embodies the attributes aforenoted.

It is a further object of this invention to provide a carton which is possessed of superior top to bottom strength and is capable of accommodating a wide variety of fragile products.

Further and additional objects will appear from the description, accompanying drawings and appended claims.

In accordance with one embodiment of this invention, a carton is provided which comprises a bottom section having upstanding walls delimiting an open top, and a cover section which is adapted to be moved into an overlying reigstered closed relation with respect to the bottom section open top. The cover section has depending walls which delimit an open bottom.

One wall of the bottom section has formed thereon upwardly extending first and second protuberances. The first protuberance is provided with a pocket which is accessible from the outwardly facing open front side of the protuberance. The second protuberance is spaced sidewise from the first protuberance. A wall of the cover section is adapted to be disposed adjacent to and in overlying relation with respect to the open front side of the first protuberance and to be disposed adjacent to but inwardly of the second protuberance. The cover section one wall is provided with a releasable lock means which is adapted to interlock with the first protuberance pocket and thereby retain the cover section in its closed position. The cover section one wall also includes an inwardly projecting portion which rests upon the top of the first protuberance, when the cover section is in its bottom section-closing position.

DESCRIPTION For a more complete understanding of the invention, reference should be made to the drawings wherein:

FIG. 1 is a top plan view of one form of the improved carton shown in a fully opened condition ready for loadmg.

FIG. 2 is a front elevational view showing the carton of FIG. 1 in a closed condition.

FIG. 3 is a right end elevational view of the carton of FIG. 1 shown in its fully opened condition.

FIG. 4 is a right end elevational view of the carton shown in FIG. 2 and with a portion of the carton removed so as to expose the interlocking engagement between the cover and bottom sections.

FIG. 5 is a fragmentary sectional view taken along line 55 of FIG. 2.

FIG. 6 is similar to FIG. 1 but showing a second form of the improved carton.

FIG. 7 is similar to FIG. 2 but showing the form of carton illustrated in FIG. 6 and with the left-hand lock means in an unlocked position and with the right-hand lock means in a locked position.

FIG. 8 is similar to FIG. 4 but of the form of carton illustarted in FIG. 7.

FIG. 9 is a fragmentary front elevational view of a third form of the improved carton and showing the cover section thereof in a closed position and the lock means in an interlocking position.

FIG. 10 is a fragmentary sectional view taken along line 1010 of FIG. 9.

Referring now to the drawings and more particularly to FIGS. 1-4, one form of an improved molded carton is shown which in this instance is adapted to accommodate a dozen eggs or similar fragile articles, not shown. The carton 20 in the illustrated embodiment is a type commonly referred to as a 2 x 6 style which is molded or formed from pulp, expanded polystyrene, polyethylene, or other suitable material.

Carton 20 includes a bottom or tray section 21 having formed therein twelve egg-accommodating cells 22 which are arranged in two parallel rows of six cells each. The bottom section 21 has an open top which is substantially delimited by a peripheral flange 23. The flange extends laterally outwardly from the upstanding walls forming the bottom section. The portion 23a of the flange disposed along the front of the bottom section 21 is interrupted by a plurality of upwardly extending first protuberances 24a, b, c, d and e, which are aligned between pairs of cells forming the front or adjacent row of cells. Each first protuberance is of like construction and is provided with an interior pocket which is formed by upwardly tapering side walls 25 and a transverse or horizontal top wall 2 6. The front or outwardly facing side 25' of the protuberance is open so as to provide access to the pocket. Access to the pocket is also permissible from beneath the protuberance by reason of the bottom 26' thereof being open, see FIG. 4. Each first protuberance terminates a substantial distance above the plane of the flange 23, See FIGS. 3 and 4.

Each interrupted portion 23a of flange 23 is provided with a second protuberance 27, which is in the form of an upturned lip, see FIG. 4. A lip is disposed on each side of each first protuberance, see FIG. 2. Each lip, in the illustrated embodiment, is of like configuration and has the upper edge 27 thereof offset outwardly so as to add stiffness to the lip. The function of the lips will be discussed more fully hereinafter.

The carton also comprises a cover section 28 which has a top panel 30 and depending walls 31 which terminate in an outwardly extending peripheral flange 32, the latter delimiting an open bottom. The corresponding rear portions of flanges 23 and 32 are interconnected so as to form a hinge 33. When cover section 28 is moved to its closed position relative to the bottom section 21, the flanges 23 and 32 are disposed in registered relation.

The top panel 30 of the cover section 28 may be provided with a center depending post 34, as shown, which is adapted to engage a corresponding upstanding hollow post 35 formed in the bottom section 21 between the rows of cells, when the cover section is in a closed position with respect to the bottom section.

The front depending wall 31a of the cover section is provided with a pair of openings 36 which are in spaced relation so as to be aligned with the endmost protuberances 24a and 242. Each opening 36 is subtended by an inwardly extending projection or lug 37. The lug 37 has the sides 37a thereof tapered upwardly and inwardly from the peripheral flange 32. The tapered underside of the lug permits the latter to readily cam over the top of the aligned protuberance 24a or 2 when the cover section is moved to its closed position. Once the upper edge 37b of the lug 37 has moved past the top wall 26 of the protuberance, the lug, due to inherent flexibility of the carton material, will automatically snap into the pocket and thereby firmly lock the cover section in place.

When the cover section is moved to its locked position, the portion 32a of flange 32 disposed along the front wall 31a of the cover section will be positioned behind the lips 27 formed adjacent each first protuberance 24ae. The upward extension of each lip is such that it extends above the peripheral flange of the cover section when the latter is in its locked position. By having the lips disposed outwardly of the cover section front wall, the lips prevent outwardly splaying or bulging of the front wall when the cover section is subjected to load-bearing forces.

To release the cover section from its locked position merely requires that the portion of the peripheral flange 32a, which is located beneath the lug 37, be manually forced outwardly an amount sufficient to permit the lug to clear the top panel or wall 26 of the protuberance pocket, whereupon the cover section is free to swing upwardly. If necessary, the lips disposed on either side of the protuberance 24a or e may be depressed slightly so as to facilitate outward flexing of the cover section front wall.

Former in the cover section front wall and between openings 36 are a pair of spaced inwardly extending portions or detents 38. Each detent is aligned with the protuberance 24b or 24d carried by the bottom section 21. Each detent is tapered inwardly from the cover top panel 30 and terminates in a ledge or shoulder 38a. The shoulder 38a is adapted to rest upon the top of the aligned protuberance 24b or d and thereby improved materially the top to bottom strength of the front walls of the cover and bottom sections when the carton is locked closed.

FIGS. 68 illustrate a modified carton 120 embodying the invention. The portions of carton 120 which correspond to portions previously described with regard to carton 20 are identified by the same numbers but in the one hundred series.

The principal distinctions between illustrated cartons 20 and are in regard to the lock means carried by the cover section front walls 31a and 131a. Furthermore, the detents 38 formed in carton 20 have been eliminated in the carton 120. In carton 120, the locking lugs 37 of carton 20 have been replaced by male locking elements 137. Each element is of like construction and comprises a pair of complemental members and 141. Each member has one edge thereof hingedly connected at 142 to an adjacent portion of the front wall. The other or opposite edges of the members 140-141 are interconnected by a hinge line 143. The connections 142 are in spaced relation and form opposite sides of an opening 144 formed in the front wall. The opening 144 is of such dimension that the complemental members 140 and 141 are capable, upon a predetermined external force being applied to hinge line 143, of passing therethrough so as to project inwardly or outwardly, depending upon the direction of the force applied. Due to the inherent resiliency of the members and their dimensions, the members 140 and 141 will react similar to that of a toggle switch once the hinge line 143 has moved a predetermined distance beyond the plane of the carton section wall. Thus, the complemental members will remain in either their inwardly or outwardly projecting positions until a positive predetermined external force is applied. In FIG. 8, the locking element 137 is shown in full lines in its outwardly projecting, or unlocked, position. The dotted lines, on the other hand, show the locking element 137 in its inwardly projecting, or locked, position. To move the element from a locked position to an unlocked position merely requires the finger of the housewife or user to be inserted up through the open bottom of the protuberance so that it contacts the hinge line 143 of the element whereupon the necessary outward force can be applied thereto.

Lips 127 are formed along the top front edge of the bottom section 121 in the same locations and for the same purposes as in the case of carton 20.

FIGS. 9 and 10 illustrate a third form of carton 220 embodying the instant invention. Portions of carton 220 which are similar to portions found on carton 20 are identified by like numbers except they are in the two hundred series. Carton 220 includes a locking element 237 which is the same in structure as element 137 provided on carton 120. In addition to locking element 237, carton 220 includes inwardly extending portions 244 which are formed on the front wall of the cover section 228. Portions 244 are vertically aligned with respect to the locking element 237 and are spaced above the perimeters of the openings 245 formed in the cover section front wall in connection with the locking elements.

The lower end of each portion 244 is in the form of a shoulder 246 which is adapted to engage the top 226 of the protuberance 224a carried along the front of the bottom section 221, when the cover section 228 is closed relative to bottom section 221. Additional inwardly extending portions or detents are not shown; however, if desired, they may be incorporated in the cover section located between the locking lugs.

The various cartons, as illustrated, all have the cover sections thereof hingedly connected to the bottom sections and in addition have the lock means provided only along the front of the carton. It is to be understood, of course,

that the invention is not to be limited to these precise embodiments. For example, the cover section may be completely separate and independent of the tray section, whereupon the latter would be provided with first and second protuberances along the front and rear walls of the tray section. Furthermore, the configuration of both carton sections may be varied so as to accommodate more effectively a particular type of product.

Thus, it will be seen that an improved carton has been provided which is possessed of a secure lock and is also possessed of greater top to bottom strength. The improved carton is inexpensive toproduce and is capable of accommodating a variety of fragile articles.

While several embodiments of the invention have heretofore been described, it is to be understood, of course, that the invention is not limited thereto, but further modifications are contemplated and it is intended by the appended claims to cover such modifications.

We claim:

1. A carton comprising a bottom section having an upstanding wall provided with an upwardly extending first protuberance having a pocket formed therein, said pocket having an outwardly facing open front side, and an upwardly extending stationary second protuberance formed on said Wall and disposed in sidewise spaced relation with respect to said first protuberance; and a cover section having a depending wall, said cover section being movable into overlying registered relation with respect to said bottom section whereby the wall of said cover section is disposed adjacent to and exteriorly of the outwardly facing open front side of the pocket in said first protuberance and is also disposed adjacent to and inwardly of said second protuberance, said cover section wall being provided with releasable lock means for interlockingly engaging said first protuberance pocket and retaining said cover and bottom sections in registered relation.

2. The carton of claim 1 wherein said first protuberance is stationary and the interior of the pocket thereof is accessible from below said first protuberance when said cover section is in said overlying registered relation with said bottom section, and said lock means includes a yieldable male element having a pair of foldably connected complemental members hingedly connected to spaced portions of said cover section wall, said complemental members, upon a predetermined external force being exerted thereupon, flex and pass between the spaced portions of said cover section wall and resiliently project either outwardly or inwardly of said wall depending upon the direction of the exerted force; said complemental members, only when projecting inwardly, extending into said pocket.

3. The carton of claim 1 wherein said bottom section includes stationary upwardly extending third protuberances formed on said wall, said third protuberances being spaced from said first and second protuberances and positionable interiorly of and adjacent to said cover section wall, when said cover section is disposed in overlying registered relation with said bottom section; said cover I section wall being provided with inwardly extending portions which rest upon said third protuberances when said cover section is in overlying registered relation.

4. The carton of claim 1 wherein said cover section wall is provided with an inwardly extending portion disposed above said lock means, said portion resting upon said bottom section first protuberance when said lock means is in said interlocking engagement with said first protuberance pocket.

5. The carton of claim 1 wherein said bottom section includes a plurality of article-accommodating cells and said cells are arranged in a plurality of rows; said first protuberance is stationary and is disposed adjacent a row of cells and aligned between a pair of cells forming said adjacent row.

6. The carton of claim 1 wherein said bottom and cover sections are provided with rear walls which are hingedly connected to one another, said first and second protuberances are formed on the front wall of said bottom section, both said first and second protuberances are stationary, and said lock means is provided on the front wall of said cover section.

7. The carton of claim 5 wherein there is provided a pair of spaced first protuberances, and each first protuberance is aligned between a pair of cells forming said adjacent row.

References Cited UNITED STATES PATENTS 3,285,491 11/1966 Bessett 229 X 3,391,845 7/1968 Bessett 2292.5 3,430,838 7/1969 Bessett 229'45 X DAVIS T. MOORHEAD, Primary Examiner U.S. Cl. X.R. 22945 

